Wireless system and method for measuring an operative condition of a machine

ABSTRACT

A system includes a sensor configured to be disposed within a reservoir of a machine having moving parts that are lubricated by a liquid in the reservoir. The sensor is configured to obtain a measurement of the liquid that is representative of at least one of a quantity or quality of the liquid in the reservoir. The system also includes a device body operably coupled to the sensor. The device body has a processing unit that is operably coupled to the sensor and configured to generate first data signals representative of the measurement of the liquid. The device body also includes a transmitter that is configured to wirelessly communicate the first data signals to a remote reader.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of and claims priority to U.S. patentapplication Ser. No. 15/678,403, which was filed 16 Aug. 2017, which isa continuation of U.S. patent application Ser. No. 14/421,245, which wasfiled 12 Feb. 2015, which is a national stage application ofInternational Patent Application No. PCT/US2013/055983, filed on 21 Aug.2013, which claims the benefit of U.S. Provisional Patent ApplicationNo. 61/692,230, which was filed 22 Aug. 2012. The entire disclosures ofthese applications are incorporated herein by reference.

FIELD

One or more embodiments of the subject matter described herein generallyrelate to systems and methods for detecting an operative condition of amachine or a component of the machine that has movable parts.

BACKGROUND

Many industrial machines (e.g., locomotives, trucks, earth-movingequipment, windmills, and the like) include elements or assemblies(e.g., mechanical drive trains) that operate within difficultenvironments and/or endure substantial amounts of thermal or torsionalstress as well as shock and vibration. It is often desirable to monitora condition of an element or assembly so that it may be replaced orrepaired before severe and permanent damage is sustained by the machine.Often, fluid lubricants are used to provide lubrication and cooling toincrease performance of the machine and/or to increase the lifetimeoperation of the machine. Lubricants reduce the friction between twoparts that engage each other and may also dissipate heat that isgenerated by the friction between the two parts. As one specificexample, speed control from a traction motor or other provider ofmechanical power may be accomplished with a gear train or drive train.Gear trains typically include at least two gears that engage each other.For instance, teeth of a first gear (e.g., pinion gear) may engage teethof a larger gear at a gear mesh. It is common for the gears to belubricated by a lubricant (e.g., oil) to reduce the friction between thegears and to facilitate the dissipation of heat that is generated duringoperation. For the gears to be suitably lubricated, a designated amountof lubricant is available for use by the gears.

A gear train may include a gear case that surrounds one or more parts ofthe gear train. The gear case has a reservoir for holding the lubricant.At least one of the gears may move through the reservoir to lubricatethe gear and consequently the gear mesh. At least one of the gears maybe coupled to a shaft that projects out of the gear case. To preventleakage from the reservoir or the gear case, the interface between theshaft(s) and the gear case is sealed.

The sealed interfaces, however, are often exposed to harsh conditions.For example, gear trains of locomotives are frequently exposed to largedifferences in temperature, humid environments, dry environments,abrasive dirt or grime, and/or challenging vibratory states. Theseconditions may cause a failure in the sealed interface thereby resultingin leakage of the lubricant. When an insufficient supply of lubricant isavailable for the gears, the machine may be susceptible to gear train orrolling element bearing damage that results in a locked axle condition.In the case of locomotives, locked axles may require the locomotive tobe removed from service and sent to a facility for repair. Both theremoval and repair of the locomotive may be time-consuming and costly.Furthermore, the lost productivity of the locomotive is also costly.

In addition to having a sufficient amount of lubricant, it is alsodesirable for the lubricant to have a sufficient quality duringoperation. For example, lubricants in a reservoir can becomecontaminated by water, metallic particles, and non-metallic particles.Contaminated fluids may lead to damaged parts or a decreased performanceof the machine. In addition, the lubricant may age due to repetitivethermal and viscous cycles resulting in the loss of fluid propertiessuch as viscosity.

Conventional methods of inspecting fluids of a machine include visualinspection of the fluid (e.g., dipsticks) or a sensor that is directlywired to a system. However, these methods may not be practical and/ormay have limited capabilities. For example, due to the configuration ofsome machines, it may be difficult to visually inspect the fluid. Also,hardwired sensors may not be suitable for machines that frequently moveand/or are exposed to harsh conditions.

In addition to detecting the quantity and/or the quality of a liquidused by a machine, it may be desirable to obtain other informationregarding an operative condition of a machine. For example, when anindustrial machine is operating properly, the machine may have known orexpected vibratory states. However, when a part of the machine isdamaged or otherwise not operating properly, the vibrations of themachine may change. Therefore, it may be desirable to detect thevibrations of certain elements in a machine to monitor a health of theelements, other components of the machine, or the machine overall.

BRIEF DESCRIPTION

In accordance with an embodiment, a system (e.g., a monitoring system)is provided that includes a sensor configured to be disposed within areservoir of a machine having moving parts that are lubricated by aliquid in the reservoir. The sensor is configured to obtain ameasurement of the liquid that is representative of at least one of aquantity or quality of the liquid in the reservoir. The system may alsoinclude a device body operably coupled to the sensor. The device bodyhas a processing unit that is operably coupled to the sensor andconfigured to generate first data signals representative of themeasurement of the liquid. The device body also includes a transmitterthat is configured to wirelessly communicate the first data signals to aremote reader.

In an embodiment, a system (e.g., a monitoring system) is provided thatincludes a sensor that is configured to be engaged to a mechanicalelement of a drive train to obtain a measurement of a vibratory state ofthe mechanical element. The measurement is representative of anoperative condition of the drive train. The system includes a devicebody that has a processing unit operably coupled to the sensor. Theprocessing unit is configured to generate first data signalsrepresentative of the measurement. The device body also includes atransmitter that is configured to wirelessly communicate the first datasignals to a remote reader.

In an embodiment, a method (e.g., a method for monitoring an operativecondition of a machine) includes receiving data signals from a wirelessdevice of a machine having a drive train. The wireless device includes adevice body directly coupled to the drive train. The device bodyincludes a transmitter for wirelessly transmitting the data signals. Thedata signals may be based on a measurement of an operative condition ofthe drive train. The method also includes, responsive to determiningthat the drive train is operating improperly, generating signals toschedule at least one of maintenance of the drive train or replacementof an element of the drive train.

In an embodiment, a system (e.g., a monitoring system) includes asignal-processing module that is configured to receive data signals froma wireless device of a machine having a drive train. The data signalsare based on a measurement of an operative condition of the drive train.The signal-processing module is configured to determine, based on thedata signals, whether the drive train is operating improperly.Optionally, the system also includes a planning module that isconfigured to generate an operating plan that is based on the operativecondition.

While multiple embodiments are disclosed, still other embodiments of thedescribed subject matter will become apparent from the followingDetailed Description, which shows and describes illustrative embodimentsof disclosed inventive subject matter. As will be realized, theinventive subject matter is capable of modifications in various aspects,all without departing from the spirit and scope of the described subjectmatter. Accordingly, the drawings and detailed description are to beregarded as illustrative in nature and not restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of a system in accordance with an embodiment.

FIG. 2 is a side view of a drive train in accordance with an embodiment.

FIG. 3 is a partially exploded view of a gear case that may be used bythe drive train of FIG. 2.

FIG. 4 is a side view of a capacitive-type sensor in accordance with anembodiment.

FIG. 5 is a schematic view of a magnetic float/reed switch sensor inaccordance with an embodiment.

FIG. 6 is a schematic view of an accelerometer in accordance with anembodiment.

FIG. 7 is a schematic diagram of a wireless device formed in accordancewith an embodiment.

FIG. 8 is a schematic diagram of a wireless device formed in accordancewith an embodiment.

FIG. 9 is a cross-section of a portion of a wireless device utilizingthe sensor of FIG. 4 in accordance with an embodiment.

FIG. 10 is a cross-section of a portion of a wireless device utilizingthe sensor of FIG. 4 in accordance with an embodiment.

FIG. 11 is a cross-section of a wireless device utilizing the sensor ofFIG. 5 in accordance with an embodiment.

FIG. 12 is a cross-section of a portion of a wireless device formed inaccordance with an embodiment.

FIG. 13 is a front view of the wireless device of FIG. 13.

FIG. 14 is a schematic view of a locomotive and illustrates a pluralityof components of the locomotive in accordance with an embodiment.

FIG. 15 illustrates a system in accordance with an embodiment forobtaining data signals from one or more wireless devices.

FIG. 16 is a flowchart illustrating a method in accordance with anembodiment.

DETAILED DESCRIPTION

Embodiments described herein include various systems, assemblies,devices, apparatuses, and methods that may be used in a connection withobtaining one or more measurements of a machine. The measurement(s) maybe representative or indicative of an operative condition of themachine. As used herein, an “operative condition of the machine” mayrefer to an operative condition of the machine as a whole or anoperative condition of a component (e.g., element, assembly, orsub-system) of the machine. As used herein, the term “operativecondition” relates to a present state or ability of the component and/ora future state or ability. For example, the measurement may indicatethat a component is not functioning in a sufficient manner, is damaged,is likely to be damaged if it continues to operate in a designatedmanner, is not likely to perform appropriately under designatedcircumstances, and/or is likely to cause damage to other components ofthe machine.

As an example with respect to locomotives or other rail vehicles, one ormore measurements obtained from a locomotive or other rail vehicle mayindicate that a lubricant in the component (e.g., drive train, gearbox,engine, and the like) is low or has an insufficient quality. Embodimentsset forth herein may generate an operating plan that is based on themeasurement(s). For instance, the operating plan may includeinstructions to disable an axle or to limit tractive and/or brakingefforts of the axle. The operating plan may indicate which element ofthe gearbox should be replaced and/or how the machine is to be operateduntil the gearbox is replaced. Such operating plans are described ingreater detail below.

The measurement may be one of a plurality of measurements that areanalyzed according to embodiments described herein. For instance,embodiments may comprise analyzing multiple measurements that wereobtained at different times from a single sensor to determine anoperative condition of the machine. By way of example, a series ofmeasurements from a single sensor in a gear case may indicate that alubricant level has substantially changed and, thus, the gear case isleaking. Embodiments may also comprise analyzing measurements from aplurality of sensors of the same type. For example, machines may includemultiple gearboxes. Vibration measurements from the gearboxes mayindicate that one of the gearboxes is operating differently than theothers and, thus, may be damaged or in need of maintenance. Embodimentsmay also comprise analyzing different types of measurements to determinean operative condition of the machine. For example, the vibrationmeasurements may be analyzed in light of the speed at which the gearsare driven and/or current environmental conditions. Additionalmeasurements or factors are set forth below.

The measurements may be wirelessly transmitted from a device to areader, which may also be referred to as a receiver. For example, radiowaves representative of the measurement(s) may be transmitted from atransmitter (e.g., antenna) of the wireless device to a remote reader.The reader may be a handheld reader (e.g., capable of being carried in asingle hand by a technician) or an otherwise movable reader. In someembodiments, the reader may have a fixed position. For example, forembodiments in which the machine is a vehicle, the reader may have astationary position along a designated path that is traversed by thevehicle (e.g., railroad tracks, weighing stations, tollbooths). When avehicle passes the reader, the reader may interrogate one or morewireless devices to obtain measurements. Remote readers may also belocated on-board the vehicle. For example, a locomotive or other railvehicle may have a control system that receives data from multiplesources, including one or more wireless devices that communicate themeasurements to the control system.

The measurement may be detected or obtained by a sensor when the devicehaving the sensor is interrogated by the reader. Alternatively oradditionally, the sensor may obtain data at designated intervals (e.g.,one measurement/hour, one measurement/minute, and the like) and/or whena designated event occurs. For example, measurements may only beobtained after the vehicle has been interrogated or after the vehiclehas remained stationary for a certain amount of time (e.g., tenminutes). In some embodiments, the wireless device includes a storageunit (e.g., memory) where multiple measurements may be stored or logged.The wireless devices may also include a power source that is integral tothe device. Examples of electrical power sources include batteries andenergy harvesting devices. Energy harvesting devices convert energy inthe surrounding environment, such as kinetic energy (e.g., vibrations),thermal energy, and electromagnetic energy. In particular embodiments,the wireless devices may include or be coupled to a vibratory energyharvesting device that converts kinetic energy into electrical energy.

The foregoing description of certain embodiments of the presentinventive subject matter will be better understood when read inconjunction with the appended drawings. To the extent that the figuresillustrate diagrams of the functional blocks of various embodiments, thefunctional blocks are not necessarily indicative of the division betweenhardware and circuit. Thus, for example, one or more of the functionalblocks (for example, controllers or memories) may be implemented in asingle piece of hardware (for example, a general purpose signalprocessor, microcontroller, random access memory, hard disk, and thelike). Similarly, the programs may be stand-alone programs, may beincorporated as subroutines in an operating system, may be functions inan installed software package, and the like. The various embodiments arenot limited to the arrangements and instrumentality shown in thedrawings.

FIG. 1 is a schematic diagram of a system 100 formed in accordance withone embodiment. The system 100 is configured to obtain one or moremeasurements that are representative of an operative condition of amachine 102 or a component of the machine 102 (e.g., element, assembly,or sub-system of the machine 102). By way of example only, the machine102 may be a motive machine or vehicle, such as an off-highway vehicle(e.g., vehicles that are not designed or allowed by law or regulation totravel on public roads, highways, and the like). Off-highway vehiclesinclude locomotives, mining vehicles, construction equipment,agricultural equipment, industrial equipment, marine vessels, and thelike. In some cases, the vehicle may be part of a vehicle consist inwhich multiple vehicles are linked directly or indirectly to one anotherin a common vehicle system (e.g., train). In some embodiments, themachine is an automobile. In other embodiments, the machine is notconfigured to travel. For example, the machine may be a windmill or apower-generating turbine.

The operative condition may relate to a health or status of a designatedcomponent of the machine. Non-limiting examples of such componentsinclude a gearbox, a gear case, an air compressor, a turbo-charger, or adrive train. The measurement may be analyzed to determine, for example,that a component is damaged, is operating improperly (e.g.,insufficiently or not at all), and/or is operating in a manner that willlead to or cause greater damage to the component or other component ofthe machine 102.

In particular embodiments, the operative condition is determined basedon an amount or quality of liquid used by the machine 102 and/or avibratory state of the machine 102. For instance, in some embodiments,the component may be a gear case that has a reservoir for storing alubricant liquid. A low level or quantity of the liquid in the reservoirmay indicate that the gear case is damaged. In particular, a low levelor quantity may indicate that the gear case is leaking the liquid. Inother embodiments, a component may have a particular vibratory state(s)when the component is operating properly. For example, a mechanicalelement may be configured to oscillate in a known or expected mannerduring operation. However, if the mechanical element is damaged oroperating improperly, the mechanical element may have a differentvibratory state.

As shown, the system 100 may include a wireless device 104 that isconfigured to wirelessly communicate data signals to a remote reader106. The data signals may represent the measurement(s) obtained by thewireless device 104. To this end, the wireless device 104 may include asensor 108, a processing unit 110, and a transmitter 112. The sensor 108is configured to measure an operating parameter of the machine 102 andthereby obtain a measurement. In some embodiments, the sensor 108includes a detector or transducer 114 and an activator 116. Theactivator 116 may be configured to provide a stimulus (e.g., soundwaves, light, electric current, etc.) that causes a response by acomponent-of-interest or is affected by the component-of-interest. Thedetector 114 may be configured to detect the response that is caused bythe stimulus or the affect that the component-of-interest has on thestimulus. For example, the stimulus may be sound waves that are detectedto determine a liquid level (e.g., sonar). The stimulus may be lightsignals that are projected by a laser into a liquid to determine howmuch of the light signals are absorbed by the liquid. Another stimulusmay be electric current. In other embodiments, the sensor 108 does notinclude an activator 116. Instead, the detector 114 may detect sound,vibrations, light, temperature, electrical properties, or otherproperties that occur in the environment without a stimulus provided byan activator.

The processing unit 110 is operably coupled to the sensor 108. Theprocessing unit 110 is configured to receive measurement signals fromthe sensor 108 and process the measurement signals to provide datasignals. The processing unit 110 may be an analog-to-digital converter(ADC). Alternatively or in addition to the ADC, the processing unit 110may include a logic-based device that transforms the measurement signalsinto data signals. The data signals may then be configured to betransmitted to the reader 106 by the transmitter 112. For example, theprocessing unit 110 may be a computer processor, controller (e.g.,microcontroller) or other logic-based device that performs operationsbased on one or more sets of instructions (e.g., software). Theinstructions on which the processing unit 110 operates may be stored ona tangible and non-transitory (e.g., not a transient signal) computerreadable storage medium, such as a memory. The memory may include one ormore types of memory, such as hard drives, flash drives, RAM, ROM,EEPROM, and the like. Alternatively, one or more of the sets ofinstructions that direct operations of the processing unit 110 may behard-wired into the logic of the processing unit 110, such as by beinghard-wired logic formed in the hardware of the processing unit 110.

The transmitter 112 is operably coupled to the processing unit 110 andis configured to wirelessly communicate the data signals to the reader106. In some embodiments, the transmitter 112 is a transceiver that isconfigured to transmit the data signals and receive other signals, suchas interrogation signals from the reader 106.

In some embodiments, the sensor 108, the processing unit 110, and thetransmitter 112 are localized within and/or attached directly to themachine such that the sensor 108, the processing unit 110, and thetransmitter 112 are proximate to each other and form a single device.The sensor 108, the processing unit 110, and the transmitter 112 may bein a localized spatial region of the machine that is separate from acomputing system that controls operation of the machine. For example,the processing unit 110 and the transmitter 112 may be integrated withthe same component such that the processing unit 110 and the transmitter112 have fixed positions with each other. More specifically, theprocessing unit 110 and the transmitter 112 may be at least partiallyintegrated onto a common component (e.g., circuit board) and/orpositioned within a common container or housing that is coupled to themachine. The common container may not be coextensive with the machineand, instead, may be a separate component that is attached to ordisposed within the machine-of-interest. By way of example only, some orall the components of the processing unit 110 and the transmitter 112may be located within 50 cm of each other, 20 cm of each other, 10 cm ofeach other or, more particularly, within 5 cm of each other.

In some embodiments, the processing unit 110 and the transmitter 112 maybe part of a common RFID unit (e.g., tag, chip, card, and the like).Optionally, the sensor 108 may also be part of the common RFID unit. Inother cases, the sensor 108 is separate from, but operably coupled to,the RFID unit and is only a short distance from the RFID unit. Forexample, the sensor 108 may be located within 50 cm or less of the RFIDunit and communicatively coupled via wires or wireless communication.The RFID unit may be formed in accordance with RFID technology, whichmay include integrated circuit technology. For example, the RFID unitmay be an electronic circuit that is capable of wireless communication.In some instances, the RFID unit may satisfy one or more establishedRFID standards and/or guidelines, such as standards and guidelinesformed by the International Organization for Standardization (ISO), theInternational Electrotechnical Commission (IEC), ASTM International, theDASH? Alliance, EPCglobal, the Financial Services Technology Consortium(FSTC).

In certain embodiments, the wireless device 104 is not physicallyelectrically connected (e.g., not connected by wires or otherconductors) to any of the one or more computers or othercontroller-based units in the machine. For example, in the context oftrains, the wireless device 104 may be partially disposed within areservoir and/or attached to a wall that defines the reservoir and isnot physically electrically connected to the computing system thatcontrols operation of the train. In such embodiments, the data signalsfrom the wireless device 104 may be wirelessly transmitted from thewireless device 104 to, for example, a reader that is on-board oroff-board. More specifically, the data signals may not be transmittedvia wire/cables or other physical electrical connections. In one or moreembodiments, at least portions of the processing unit 110 and thetransmitter 112 may be directly connected to a wall that defines thereservoir (e.g., a wall that bears a pressure of and/or contacts theliquid in the reservoir) and/or to a structure immediately connected tothe wall (e.g., support structure of the reservoir, gear case, or thelike).

Various forms of wireless communication may be transmitted and receivedby the wireless device 104. For example, the transmitter 112 may beconfigured to receive and/or transmit radio signals, optical signals,signals based on sound, or signals based on magnetic or electric fields.In particular embodiments, the transmitter 112 is configured to receiveand/or transmit radio signals in one or more radio frequencies. Thewireless signals may be transmitted along a narrow radio band. In narrowband transmission, a single carrier frequency is used. Alternatively,the wireless signals may be transmitted within a spectrum of radiofrequencies. For example, in spread spectrum transmission, the signalsmay be transmitted over a number of different radio frequencies within aradio band. The data signals may be modulated for transmission inaccordance with any one of a number of modulation standards, such asfrequency-hopping spread spectrum (FHSS), direct-sequence spreadspectrum (DSSS), or chirp spread spectrum (CSS).

One wireless communication standard that may be used by embodimentsdescribed herein is IEEE 802.15.4. The IEEE 802.15.4 standard mayoperate within one of three frequency bands: (1) 868.0-868.6 MHz; (2)902-928 MHz; or (3) 2400-2483.5 MHz. A number of channels may be used ineach of the frequency bands. Embodiments may also use frequency bandsthat are associated with RFID technology, such as 120-150 kHz, 13.56MHz, 865-868 MHz, 902-028 MHz, 2450-5800 MHz, or 3.1-10 GHz. Ultrawideband (UWB) may also be used.

In some embodiments, a transmission range of the data signals and/or thesignals from the reader 106 is about 0-10 meters or from about 0-20meters. In other embodiments, the transmission range may be greater,such as up to 100 meters or more.

Various embodiments may be based on or consistent with radio frequencyidentification (RFID) technology. For example, the wireless device 104may be a passive sensor, a semi-passive sensor, or an active sensor. Apassive sensor may not include a power source. Instead, the power may bebased on inductive coupling or backscatter coupling with the reader. Asemi-passive sensor may include a power source for only designatedfunctions. For example, a battery and/or an energy harvesting device maybe used to increase the transmission distance. The passive andsemi-passive sensors may be particularly suitable for when the reader ispresent (e.g., within transmission range so that the sensors can bepowered by the reader). An active sensor may include a power source forpowering multiple functions (e.g., detection, reception, andtransmission). Active sensors may be used in embodiments in which thereader is configured to only receive data signals and not transmitinterrogation signals.

The reader 106 may be operably connected to a control system 118 havinga signal-processing or diagnostic module 120 and, optionally, a planningmodule 122. Like the processing unit 110, the modules 120, 122 may be acomputer processor, controller (e.g., microcontroller), or otherlogic-based device that performs operations based on one or more sets ofinstructions. The instructions on which the modules 120, 122 operatesmay be stored on a tangible and non-transitory (e.g., not a transientsignal) computer readable storage medium, such as a memory.Alternatively, one or more of the sets of instructions that directoperations of the modules 120, 122 may be hard-wired into the logic ofthe modules 120, 122. The module 120, 122 may be located on separatedevices (e.g., separate processors) or may be located on commonprocessor.

The signal-processing module 120 may be configured to determine, basedon the data signals received by the reader 106, whether the machine 102is operating improperly. The signal-processing module 120 may determinewhether the machine 102 is operating properly or improperly by analyzingthe data signals that are representative of the measurements. Forexample, the signal-processing module 120 may use a look-up table orother databases that provides acceptable ranges of operation. If themeasurement based on the data signals is not within the range, thesignal-processing module 120 may determine that the machine 102 is notoperating properly. In some cases, based on the measurement(s), thesignal-processing module 120 may be able to determine whether aparticular component of the machine 102 needs maintenance, repair, orreplacement or whether the machine 102 requires an overhaul of asub-system.

Based on the measurement(s), the signal-processing module 120 mayrequest that an operating plan be generated by the planning module 122.The operating plan may be configured to improve the performance of themachine 102 and/or to limit the performance of the machine 102 toprevent damage or additional damage. The operating plan may includeinstructions for replacing, maintaining, modifying, and/or repairing adesignated component or components of the machine 102.

The operating plan may be based on the operative condition, which is atleast partially a function of the measurement(s) obtained. For instance,if a capacitive measurement indicates that the liquid level is less thansufficient, but a substantial amount remains in the gear case, then theoperating plan may include instructions for refilling the liquid at afirst facility and then resealing the gear case at a second facilitylocated further away. However, if a capacitive measurement indicatesthat the liquid level quickly reduced to little or no measurable amountof liquid, then the operating plan may instruct that the gear case bereplaced at a designated facility.

In the context of a locomotive or other vehicle, the operating plan mayinclude instructions for controlling tractive and/or braking efforts ofthe vehicle. In particular, the operating plan may be partially based onthe measurements of the operative condition of the machine. Theinstructions may be expressed as a function of time and/or distance of atrip along a route. In some embodiments, travel according to theinstructions of the operating plan may cause the vehicle to reduce astress on a component-of-interest of the machine than the componentwould typically sustain during normal operation. For example, theoperating plan may instruct the vehicle to reduce horsepower deliveredto an axle, to intermittently drive the axle, or to disable the axlealtogether. The vehicle may be autonomously controlled according to theoperating plan or the instructions of the operating plan may bepresented to an operator of the vehicle so that the operator canmanually control the vehicle according to the operating plan (alsoreferred to herein as a “coaching mode” of the vehicle).

In some embodiments, the operating plan that is generated when it isdetermined that the machine is operating improperly is a “revised”operating plan that supersedes or replaces another operating plan. Morespecifically, due to the newly acquired measurements, the control systemmay determine that the currently-implemented operating plan should bemodified and, as such, may generate a revised operating plan to replacethe other.

Operating plans may be optimized to achieve designated goals orparameters. As used herein, the term “optimize” (and forms thereof) arenot intended to require maximizing or minimizing a characteristic,parameter, or other object in all embodiments described herein. Instead,“optimize” and its forms may include increasing or decreasing (asappropriate) a characteristic, parameter, or other object toward adesignated or desired amount while also satisfying other conditions. Forexample, optimized stress levels on a component may not be limited to acomplete absence of stress or that the absolute minimum amount ofstress. Rather, optimizing the stress level may mean that the stress iscontrolled, while also satisfying other conditions (e.g., speed limits,trip duration, arrival time). For example, the stress sustained by acomponent may be controlled so that the vehicle may arrive at itsdestination without the component being severely damaged.

The planning module 122 is configured to use at least one of vehicledata, route data (or a route database), part data, or trip data togenerate the operating plan. The vehicle data may include information onthe characteristics of the vehicle. For example, when the vehicle systemis a rail vehicle, the vehicle data may include a number of rail cars,number of locomotives, information relating to an individual locomotiveor a consist of locomotives (e.g., model or type of locomotive, weight,power description, performance of locomotive traction transmission,consumption of engine fuel as a function of output power (or fuelefficiency), cooling characteristics), load of a rail vehicle witheffective drag coefficients, vehicle-handling rules (e.g., tractiveeffort ramp rates, maximum braking effort ramp rates), content of railcars, lower and/or upper limits on power (throttle) settings, etc.

Route data may include information on the route, such as informationrelating to the geography or topography of various segments along theroute (e.g., effective track grade and curvature), speed limits fordesignated segments of a route, maximum cumulative and/or instantaneousemissions for a designated segment of the route, locations ofintersections (e.g., railroad crossings), locations of certain trackfeatures (e.g., crests, sags, curves, and super-elevations), locationsof mileposts, and locations of grade changes, sidings, depot yards, andfuel stations. The route data, where appropriate, may be a function ofdistance or correspond to a designated distance of the route.

Part data may include, for example, historical data or proprietary dataregarding the lifetime operability of a component. The data may includebaseline data for a designated speed and/or load on the machine.Additional factors may be part of the baseline data. For example, if thelubricant has a designated quantity in the gear case, the part data mayinclude data from identical components that operated with anapproximately equal lubricant level. The data may include how long thecomponent is capable of operating at a designated speed.

Trip data may include information relating to a designated mission ortrip, such as start and end times of the trip, start and end locations,route data that pertains to the designated route (e.g., effective trackgrade and curvature as function of milepost, speed limits), uppercumulative and/or instantaneous limits on emissions for the trip, fuelconsumption permitted for the trip, historical trip data (e.g., how muchfuel was used in a previous trip along the designated route), desiredtrip time or duration, crew (user and/or operator) identification, crewshift expiration time, lower and/or upper limits on power (throttle)settings for designated segments, etc. In one embodiment, the planningmodule 122 includes a software application or system such as the TripOptimizer™ system developed by General Electric Company.

FIG. 2 is a side view of a drive train (or final drive) 150 inaccordance with one embodiment. The drive train 150 includes a tractionmotor 152, a first (or pinion) gear 154, a second gear 156, and a baseportion or shell 160 of a gear case 158. A top portion or shell 162 ofthe gear case 158 is shown in FIG. 3. As shown in FIG. 2, the first gear154 and the second gear 156 engage each other at a gear mesh 164. Duringoperation of the drive train 150 the traction motor 152 drives the firstgear 154 by rotating an axle (not shown) coupled to the first gear 154about an axis of rotation 166. The first gear 154 may be rotated, forexample, in a counter-clockwise direction as viewed in FIG. 2. Due tothe engagement at the gear mesh 164, the first gear 154 rotates thesecond gear 156 in a clockwise direction about an axis of rotation 168.The second gear 156 is coupled to an axle (not shown) that rotates withthe second gear 156. The axle of the second gear 156 is coupled towheels (not shown) that are rotated with the axle. The wheels engage asurface (e.g., rails or tracks) to move the machine.

The gear case 158 includes a reservoir 172 that is configured to hold alubricant liquid 180 (e.g., oil). The gear case 158 has a fill or inletport 186 and a drain or outlet port 188. The liquid 180 may be providedto the reservoir 172 through the fill port 186 and drained through thedrain port 188.

As shown in FIG. 2, the second gear 156 has teeth 176 along an edge 174of the second gear 156. When the liquid 180 is held within the gear case158, the liquid 180 may have a fill level 184. FIG. 2 illustrates afirst fill level 184A and a second fill level 184B. The second filllevel 184B is lower than the first fill level 184A. In some embodiments,when the drive train 150 is operating properly, the quantity of theliquid 180 correlates to the first fill level 184A such that the edge174 of the second gear 156 is sufficiently submerged within or bathed bythe liquid 180. However, when the fill level is lowered to, for example,the fill level 184B, the edge 174 and teeth 176 may be insufficientlylubricated. Such circumstances may occur when the gear case 158 has aleak.

FIG. 3 is a partially exploded view of the gear case 158 and illustratesthe base and top portions 160, 162 before the base and top portions 160,162 are coupled to the drive train to surround the first and secondgears 154, 156. As shown, the gear case 158 may include first and secondgear-receiving openings 190, 192 that are sized to receive the first andsecond gears 154, 156 (FIG. 2), respectively. The gear-receivingopenings 190, 192 may be defined by opening edges 193-196 and the baseand top portions 160, 162 may engage each other along case edges 197,198.

When the drive train 150 is fully constructed and operational, theopening edges 193-196 engage the portions of the drive train 150 alongsealable interfaces. The case edges 197, 198 may also be coupled to eachother along a sealable interface. During operation of the drive train150, however, the interfaces may become damaged or worn such that theinterfaces are no longer sufficiently sealed. For example, when thedrive train 150 is part of a locomotive, the opening edges 193-196 orthe case edges 197, 198 may become worn, damaged, or separated such thatthe liquid 180 is permitted to escape the reservoir 172. Accordingly,the amount of liquid 180 may reduce such that the fill level 184 (FIG.2) lowers.

Embodiments described herein may be configured to detect that the amountof liquid 180 has reduced. In addition, due to the wear, damage, orseparation of the base and top portions 160, 162, the gear case 158 (orportions thereof) may exhibit different vibratory characteristics. Forexample, a gear case that is sufficiently sealed with respect to thedrive train 150 and has a sufficient fill level 184 may exhibit a firstvibratory state when the drive train 150 is driven at a first speed.However, a gear case that is insufficiently sealed with respect to thedrive train 150 and/or has an insufficient fill level 184 may exhibit asecond vibratory state that is different than the first vibratory statewhen the drive train 150 is driven at the first speed. Embodimentsdescribed herein may be configured to detect and measure the differentvibratory states. In certain embodiments, a wireless device, such asthose described herein, is at least partially disposed within thereservoir 172 and/or directly attached to a portion of the gear case158. For example, at least a portion of the wireless device 158 may bedirectly secured or affixed to a wall of the gear case 158, such as thewall that defines the reservoir 172. In some embodiments, the wirelessdevice 172 is not physically electrically connected to other componentsof the machine, such as a computing system that controls operation ofthe machine.

In addition to liquid level and vibrations, embodiments may beconfigured to detect other characteristics. For example, othermeasurements may relate to a quality (e.g., degree of contamination) ofthe liquid. Contaminants may include water, metallic particles, and/ornon-metallic particles. Furthermore, embodiments are not limited to thedrive train or a gear case of the driver train. For example,measurements that may be obtained for a drive train may also be obtainedfor a turbo-charger, an air compressor, an engine, and the like. Othercomponents of a machine may also be measured by wireless devicesdescribed herein.

FIGS. 4-6 illustrate sensors 202, 212, 222, respectively. The sensors,which may also be referred to as transducers, may be a portion of thewireless devices described herein. Each of the sensors may be configuredto measure (e.g., detect) a designated property or characteristic in theenvironment proximate to the sensor and provide a signal that isrepresentative of the measured property or characteristic. The signalprovided by the sensor may be the measurement.

Various types of measurements may be obtained by the sensors. Somenon-limiting examples include a capacitance of a liquid, a temperatureof a liquid and/or temperatures of certain parts of a machine, a fluidconduction of a liquid, a dielectric constant of a liquid, a dissipationfactor of a liquid, an impedance of a liquid, a viscosity of a liquid,or vibrations of a mechanical element. A measurement may be directlyobtained (e.g., temperature) by the sensor, or a designated measurementmay be obtained after using information provided by the sensor tocalculate the designated measurement. For example, the viscosity of theliquid may be calculated based on multiple level measurements obtainedby a sensor.

Embodiments may include a single wireless device that is configured tomeasure and communicate only a single type of measurement (e.g.,capacitance). However, in some embodiments, a single wireless device maybe configured to measure and communicate multiple types of measurements(e.g., capacitance of the liquid, temperature of the liquid, temperatureof the sensor, shock and/or vibration of the gear case, etc.). In suchembodiments, the wireless device may have multiple sensors.

The sensor 202 is configured to measure a capacitance of a liquid, suchas a lubricant in a tank (e.g., gear case). The sensor 202 ishereinafter referred to as a capacitive level probe 202. For reference,a cross-section 201 of the level probe 202 is also shown in FIG. 4. Thelevel probe 202 extends lengthwise between a leading end 208 and atrailing end 210. The level probe 202 includes an inner or measurementelectrode 204 and an outer or reference electrode 206. As shown, a space205 exists between the inner and outer electrodes 204, 206. Acapacitance of the material that exists within the space 205, such as acombination of a liquid and gas, may be measured by the level probe 202.In some embodiments, a wall of the tank that holds the liquid may beused as the reference electrode.

The level probe 202 is configured to be immersed into the liquid (e.g.,oil) held by the tank. For example, the leading end 208 may be insertedinto the liquid. As the leading end 208 is submerged, the liquid mayflow into the space 205 thereby changing a ratio of liquid to gas withinthe space 205. As such, the measured capacitance changes as the level ofthe liquid within the space 205 changes. If the liquid is a lubricant,the measured value of capacitance decreases as an amount or level of theliquid decreases. As an amount or level of the liquid increases, themeasured value of capacitance also increases.

The level probe 202 may also be configured to determine a quality of theliquid. More specifically, the level probe 202 may detect an amount orpercentage of contaminations in the liquid based on capacitancemeasurements. For example, contaminant detection may be based on adissipation factor of a dielectric of the liquid. In general, thedissipation factor is a function of an applied frequency, a liquidtemperature, a composition of the liquid (e.g., the desired compositionof the liquid), and contaminants. The dissipation factor may besubstantially independent of the base capacitance or liquid level.

In some cases, movement of the machine may cause a displacement of theliquid which may introduce an error in the measurements. Accordingly, insome embodiments, the level probe 202 is only activated when the machineor component thereof is at rest (e.g., inactive). To this end, anaccelerometer or other inertial type sensor may be part of or operablycoupled to the wireless device that includes the level probe 202. Theaccelerometer may determine that the machine is in an inactive orstationary state such that measurements may be obtained by the levelprobe 202.

As shown in FIG. 5, the sensor 212 includes a body float 214 and a reedswitch 216. The body float 214 includes a cavity 218 that is sized andshaped to receive the reed switch 216. The body float 214 is configuredto float along the reed switch 216 (e.g., vertically) based on a levelof the liquid in the reservoir. The body float 214 includes a permanentmagnet 220, and the reed switch 216 includes a magnetically actuatedswitch or switches (not shown). As the body float 214 moves up and down,the permanent magnet 220 may activate or deactivate the switch (e.g.,close or open a circuit, respectively, in the reed switch 216). Theactivated switch indicates that the body float 214 is at a designatedlevel and, consequently, that the liquid is at a designated level.

As described above, one or more embodiments may also include a sensorthat is an accelerometer. FIG. 6 illustrates one such sensor, which isreferenced as an accelerometer 222. In some embodiments, theaccelerometer 222 is a micro-electro-mechanical system (MEMS) tri-axisaccelerometer. The accelerometer 222 may be used for a variety offunctions. For example, the accelerometer 222 may be coupled to amechanical element, such as a tank, and determine whether the mechanicalelement has remained stationary for a designated amount of time. In someembodiments, other measurements (e.g. liquid level) may be obtained onlyafter it has been determined that the mechanical element has remainedstationary for the designated amount of time.

Alternatively or additionally, the accelerometer 222 may be configuredto detect vibratory states experienced by the mechanical element. Forexample, the accelerometer 222 may be configured to obtain numerousshock and vibrations measurements per second in each of x-, y-, andz-axes. For example, the accelerometer 222 may be able to log hundredsor thousands of data points per second in each of the x-, y-, andz-axes.

FIG. 7 is a schematic diagram of a wireless device 300 formed inaccordance with one embodiment. The wireless device 300 includes sensors301-304, a processing unit 306 (e.g., microprocessor), a transmitter308, an internal clock 310 (e.g., real-time clock crystal), and a memory312 (e.g., non-volatile memory). The wireless device 300 has a devicebody 315, which may include a printed circuit board (PCB) or a die(e.g., semiconductor wafer) in some embodiments. In the illustratedembodiment, the device body 315 includes the sensors 303, 304, theprocessing unit 306, the transmitter 308, the internal clock 310, andthe memory 312. In alternative embodiments, however, the wireless device300 may have multiple bodies (e.g., multiple dies) that are coupled toeach other and/or the components described herein may be separate fromthe device body 315. The sensors 301 and 302 may be operably coupled tothe device body 315 through, for example, wires 316. In otherembodiments, the sensors 301, 302 are wirelessly coupled to the devicebody 315.

The sensor 301 may be a level probe, such as the level probe 202described with respect to FIG. 4. The sensor 301 is configured to beinserted into a liquid (e.g., lubricant) of a machine. The sensor 302may be a thermometer that is configured to obtain a temperature of theliquid. The sensor 303 is an accelerometer, such as the accelerometer222 (FIG. 6), and the sensor 304 is another thermometer that isconfigured to determine a temperature of the device body 315 of thewireless device 300. Each of the sensors 301-304 is communicativelycoupled to the processing unit 306 and configured to communicate signalsto the processing unit 306. The signals may be representative of aproperty or characteristic detected by the sensor.

The processing unit 306 may be configured to store or log data (e.g.,data based on the signals obtained from the sensors) in the memory 312.In some embodiments, the processing unit 306 is configured to query thesensors 301-304 to request measurements from the sensors 301-304. Thequeries may occur at predetermined times or when a designated eventoccurs. For example, the queries may occur once an hour as determined bythe internal clock 310 until, for example, the wireless device 300 isinterrogated by a reader (not shown). At such an event, the processingunit 306 may query the sensors 301-304 for numerous data points. Forexample, the data points may be provided almost continuously afterinterrogation. The processing unit 306 may also receive data from thememory 312. The data received from the sensors 301-304 and/or the memory312 may be transformed into data signals that are communicated by thetransmitter 308 to the reader.

The wireless device 300 may be characterized as an active orsemi-passive device. For example, the wireless device 300 may include apower source 320, such as a battery (e.g., lithium thionyl chloridebattery) and/or kinetic energy harvesting device. The wireless device300 may utilize the power source 320 to increase the transmission rangeof the transmitter 308. In such embodiments, the reader may be locatedtens or hundreds of meters away from the wireless device 300. Inaddition to the transmitter 308, the power source 320 may be used tosupply power to other components of the wireless device 300, such as thesensors 301-304 or the processing unit 306.

FIG. 8 is a schematic diagram of a wireless device 350 formed inaccordance with one embodiment. The wireless device 350 may be a passivedevice such that the wireless device 350 is powered by inductive orbackscatter coupling with the reader (or some other non-internal powersource). As shown, the wireless device 350 includes sensors 351-354, aprocessing unit 356, and a transmitter 358. The wireless device 300 hasa device body 365 that includes, in the illustrated embodiment, thesensors 353, 354, the processing unit 356, and the transmitter 358. Thedevice body 365 may be formed by integrated circuit technology. Forexample, the device body 365 may include one or more printed circuitboards (PCBs). The sensors 351 and 352 may be operably coupled to thedevice body 365 through, for example, wires 366. Similar to the wirelessdevice 300 (FIG. 7), the sensors 351-354 may be a level probe, externalthermometer, an accelerometer, and an internal thermometer,respectively.

In some embodiments, the processing unit 356 executes fewer calculationsor conversions of the signals from the sensors 351-354 than theprocessing unit 306 (FIG. 7). For example, the processing unit 356 maybe an ADC that converts the analog signals from the sensors 351-354 todigital signals. The digital signals may be the data signals that arethen transmitted by the transmitter 358. In the illustrated embodiment,the processing unit 356 may only query the sensors 351-354 after beinginterrogated by a reader (not shown). More specifically, theinterrogation signals from the reader may power the processing unit 356to query the sensors 351-354 and transmit the data signals.

FIG. 9 is a cross-section of a portion of a wireless device 400 attachedto a wall 402 of a tank 401. The tank 401 may be part of a machine, suchas a locomotive or other machines described herein. The tank 401 isconfigured to have a reservoir 410 for holding a liquid (not shown),such as a lubricant. The reservoir 410 is accessed through a fill port404 of the wall 402 that is defined by interior threads 406 of the wall402 as shown in FIG. 9. The fill port 404 provides access from anexterior 408 of the tank 401 to the reservoir 410.

As shown, the wireless device 400 includes a sensor 412, a device body414, and an intermediate cable portion 416 that joins the sensor 412 andthe device body 414. The wireless device 400 also includes a couplingcomponent 418 that is configured to be secured to the device body 414through, for example, fasteners 420 and attached to the wall 402. In theillustrated embodiment, the coupling component 418 includes threads 422that complement and are configured to rotatably engage the threads 406of the wall 402. However, in other embodiments, different methods ofattaching the coupling component 418 to the tank may be used, such aslatches, interference fits (e.g., plugs), and/or adhesives.

To assemble the wireless device 400, the coupling component 418 may berotatably engaged to the wall 402. The sensor 412 and the cable portion416 may be inserted through an opening 424 of the coupling component 418and the fill port 404. As shown, the coupling component 418 has a matingface 428 that faces in a direction away from the wall 402. The cableportion 416 has a mating end 426 that is located in the exterior 408 ofthe tank 401 and may be pressed toward the mating face 428 with a gasket430 located therebetween. The device body 414 has a cable opening 432that receives an end of the cable portion 416. The device body 414 maybe secured to the cable portion 416 and the coupling component 418 usingthe fasteners 420. As shown, the cable portion 416 includes a fillchannel 436 that permits access to the reservoir 410. During operation,the fill channel 436 may be closed with a plug 438 at the mating end 426of the cable portion 416.

The sensor 412 may be similar or identical to the level probe 202described with respect to FIG. 4. For example, a trailing end 440 of thesensor 412 is shown in FIG. 9. The trailing end 440 is coupled to wires442 that communicatively couple the sensor 412 to the device body 414.In other embodiments, the sensor 462 may be similar or identical to thesensor 212 (FIG. 5). The cable portion 416 is configured to surround andprotect the wires 442 from the surrounding environment. As shown, thewires 442 terminate at a contact ring 444 along the device body 414. Thesensor 412 is configured to transmit signals to the device body 414through the wires 442 and the contact ring 444. The device body 414 isconfigured to process and transmit data signals that representmeasurements obtained by the sensor 412. The device body 414 may includean integrated circuit unit 415. Although not shown, the integratedcircuit unit 415 of the device body 414 may have a processing unit,power source, internal clock, additional sensors, and/or a transmitter,such as those described above. In some embodiments, the integratedcircuit component 415 is formed as an RFID unit.

FIG. 10 is a cross-section of a portion of a wireless device 450, whichis also configured to be coupled to a wall 452 of a tank 451. Thewireless device 450 may include similar features as the wireless device400 (FIG. 9). For example, the wireless device 450 includes a sensor462, a device body 464, and an intermediate cable portion 466 that joinsthe sensor 462 and the device body 464. The wireless device 450 alsoincludes a coupling component 468 that is configured to be secureddirectly to the device body 464 and the cable portion 466 throughfasteners 470. In the illustrated embodiment, the coupling component 468is rotatably engaged to the wall 452 in a similar manner as the couplingcomponent 418 (FIG. 9). However, other methods of attaching the couplingcomponent 468 to the wall may be used.

To assemble the wireless device 450, the coupling component 468 may berotatably engaged to the wall 452. The sensor 462 and the cable portion466 may be inserted through the coupling component 416 and a fill port454 of the wall 452. The device body 464 may be encased within a matingend 476 of the cable portion 466. As shown, the coupling component 468has a mating face 478 that faces in a direction away from the wall 452.Accordingly, the cable portion 466 and the device body 464 may besecured to the coupling component 468 using the fasteners 470. A coverbody 480 may then be positioned over the cable portion 466 to hold thedevice body 464 between the cover body 480 and the coupling component468. Unlike the wireless device 400, the cable portion 466 does notinclude a fill channel that permits access to the reservoir.

The sensor 462 may be similar or identical to the level probe 202described with respect to FIG. 4. For example, a trailing end 490 of thesensor 462 is shown in FIG. 10. The trailing end 490 is coupled to wires492 that communicatively couple the sensor 462 to the device body 464.In other embodiments, the sensor 462 may be similar or identical to thesensor 212 (FIG. 5). As shown, the wires 492 terminate at contacts 494,495 that are coupled to the device body 464. The device body 464 mayinclude an integrated circuit component 465, which, in the illustratedembodiment, is a RFID unit. The sensor 462 is configured to transmitsignals to the integrated circuit component 465 through the wires 492.Like the integrated circuit component 415, the integrated circuitcomponent 465 is configured to process and transmit data signals thatrepresent measurements obtained by the sensor 462. The integratedcircuit component 465 may include a processing unit, power source,internal clock, additional sensors, and/or a transmitter, such as thosedescribed above.

FIG. 11 is a cross-section of a portion of a wireless device 500. Thewireless device 500 may be similar to the wireless device 400 (FIG. 9)and the wireless device 450 (FIG. 10). However, as shown in FIG. 11, thewireless device 500 utilizes a sensor 502 that may be similar to oridentical to the sensor 212 (FIG. 5). The wireless device 500 alsoincludes a coupling component 504 that is configured to attach to a wall506 of a tank 508, which is a gear case in the illustrated embodiment.The coupling component 504 may be similar to the coupling componentsdescribed above. For example, the coupling component 504 may rotatablyengage the wall 506.

Also shown, the wireless device 500 includes a device body 530 that isoperably coupled to the sensor 502 through a base support 510 and anintermediate beam 512. The base support 510 is disposed within anopening 514 of the coupling component 504. The beam 512 extends betweenand joins the sensor 502 and the base support 510. The beam 512 may befabricated from, for example, stainless steel and is configured toprovide a passageway 516 for wires 518 that communicatively couple thedevice body 530 and the sensor 502.

The base support 510 includes a mating face 520 that faces away from thetank 508. The mating face 520 has contacts 524, 525 thereon. The contact524 may be a contact pad, and the contact 525 may be a ring contact thatextends around the contact pad. A device body 530 is configured to berotatably engaged to the coupling component 504. The device body 530includes a mounting surface 532 that faces the mating face 520 and hascorresponding contacts that are configured to engage the contacts 524,525. More specifically, when the device body 530 is rotated to engagethe coupling component 504, the mounting surface 532 of the device body530 may advance toward the mating face 520 so that the contacts of thedevice body 530 press against and engage the contacts 524, 525.

Accordingly, the device body 530 may be communicatively coupled to thesensor 502. Similar to the device bodies described above, the devicebody 530 may include an integrated circuit component 515 having aprocessing unit and a transmitter (not shown). Optionally, theintegrated circuit component 515 may also include a memory, an internalclock, and one or more other sensors. The integrated circuit component515 may transform the signals from the sensor 502 (or memory or othersensors) into data signals. The data signals may then be transmitted toa reader (not shown). In some embodiments, the integrated circuitcomponent 515 is formed as an RFID unit.

FIG. 12 is a cross-section and FIG. 13 is a front view, respectively, ofa portion of a wireless device 550. The wireless device 550 may includea sensor (not shown) and a device body 552 that are communicativelycoupled through wires 554. The sensor may be similar to the sensor 202(FIG. 4) or the sensor 212 (FIG. 5). The device body 552 is secured to afaceplate 556 that is coupled to an exterior surface of a tank 560 (FIG.13). FIGS. 12 and 13 illustrate an embodiment in which no electricalcontacts are required along the device body 552 to electrically join thesensor. Instead, wires 554 (FIG. 12) from the sensor may extend throughpotting 562 that mechanically couples the sensor to the tank 560. Likethe wireless device 400 (FIG. 9), the wireless device 550 may permitaccess to a fill port 566 through a plug 568. Although not shown, thedevice body 552 may include an integrated circuit component, such asthose described above, that processes data signals and transmits datasignals. The integrated circuit component may be an RFID unit that isdirectly coupled to one of the wires 554.

FIG. 14 is a schematic view of a locomotive 600 and illustrates aplurality of components of the locomotive 600 that may include one ormore wireless devices, such as the wireless devices described herein.For example, the locomotive 600 may include a plurality of drive trains601 that each has a gear case 602. The locomotive 600 may also includean engine 604, a turbo-charger 606 operably coupled to the engine 604,and an air compressor 608. Each of the components may have one or moreof the wireless devices described herein operably coupled thereto. Forexample, the gear cases 602 and the engine 604 may have at least one ofthe wireless devices 202, 212, 222, 400, 450, 500, or 550 describedabove. In particular, each of the gear cases 602 and the engine 604 mayhave a reservoir that includes a liquid lubricant. The turbo-charger 606and the air compressor 608 may use, for example, an accelerometersimilar to the wireless device 222.

As shown, the locomotive 600 may also include an on-board control system610. The control system 610 can control the tractive efforts and/orbraking efforts of the locomotive 600 and, optionally, other locomotivesthat are directly or indirectly coupled to the locomotive 600.Operations of the control system 610 may be based on inputs receivedfrom an operator of the locomotive and/or remote inputs from, forexample, a control tower, a dispatch facility, or the like. In addition,the control system 610 may receive inputs from various components of thelocomotive 600. In some cases, the inputs may be data signals receivedthrough wireless communication. For example, the wireless devices of thegear cases 602, the engine 604, the turbo-charger 606, and the aircompressor 608 may be configured to wirelessly communicate data signalsto the control system 610. The control system 610 may include a reader612 for receiving the wireless data signals. The control system 610 mayalso include a signal-processing module and a planning module that aresimilar to the signal-processing and planning modules 120, 122 describedin FIG. 1. The planning module may generate operating plans for thelocomotive 600 based on the inputs received.

FIG. 15 illustrates a system 700 in accordance with one embodiment forobtaining data signals from one or more wireless devices. FIG. 16illustrates a flowchart of a method 750 that may be executed orperformed by the system 700. In some embodiments, the locomotive 600(FIG. 14) may also execute or perform the method 750. The system 700 andthe method 750 may employ structures or aspects of various embodimentsdiscussed herein. In some embodiments, certain steps of the method 750may be omitted or added, certain steps may be combined, certain stepsmay be performed simultaneously, certain steps may be performedconcurrently, certain steps may be split into multiple steps, certainsteps may be performed in a different order, or certain steps or seriesof steps may be re-performed in an iterative fashion. Likewise, thesystem 700 is not required to include each and every feature of each andevery embodiment described herein.

With respect to FIG. 15, the system 700 includes a vehicle system 702(e.g., train) including a locomotive consist 704. The locomotive consist704 may include at least one locomotive that is linked (directly orindirectly) to one or more rail cars. For example, FIG. 15 shows thelocomotive consist 704 including first and second locomotives 706, 708and a rail car 710. In other embodiments, the vehicle system 702 mayinclude more rail cars 710. Each of the locomotives 706 and 708 mayinclude a plurality of components that are each monitored by one or morewireless devices. For example, each of the locomotives 706, 708 mayinclude an engine, a turbo-charger, an air compressor, and a pluralityof gear cases, such as those described herein.

As shown in FIG. 15, the vehicle system 702 is approaching a designatedreading location 715. The reading location 715 is a maintenance facilityin the illustrated embodiment. However, the reading location 715 may bea variety of other locations that are capable of receiving wireless datasignals from the locomotives. For example, the reading location 715 maybe a depot, fuel station, wayside location, rail yard entry point orexit point, designated sections of the track(s), and the like. Thereading location 715 includes a plurality of readers 716. Each of thereaders 716 is communicatively coupled (e.g., wirelessly or throughcommunication wires) to a control system 720. Alternatively oradditionally, a handheld reader 724 may be carried by an individual andused to receive the data signals. The reader 724 may also communicatedata signals with the control system 720.

The control system 720 may include a signal-processing module and aplanning module, such as the signal-processing and planning modules 120,122 described in FIG. 1. For example, the control system 720 maygenerate operating plans that include instructions for operating thevehicle system 702 and other similar vehicle systems.

The method 750 may include receiving (at 752) data signals from one ormore of the wireless devices of a machine. In the illustratedembodiment, the machine is the vehicle system 702 or one of thelocomotives 704, 706. However, embodiments described herein are notnecessarily limited to locomotives. The machine may have one orcomponents with moving mechanical elements or parts. For example, themachine may have a drive train, engine, air compressor, and/orturbo-charger. The data signals may be representative of a measurementof an operative condition of the component. By way of example themeasurement may be at least one of a vibration measurement, acapacitance of a liquid, a temperature of a liquid, a fluid conductionof a liquid, a dielectric constant of a liquid, an impedance of aliquid, or a viscosity of a liquid. In particular embodiments, themeasurement is representative of a vibratory state of a gear case or ofa liquid condition of a lubricant held in the gear case.

The receiving operation (at 752) may include receiving the data signalsat one or more fixed readers having stationary positions. For example,the readers 716 may have fixed positions with respect to tracks 730. Thereaders 716 may be located at designated distance from the tracks 730 sothat the readers 716 are capable of receiving the data signals. Thereceiving operation (at 752) may also include receiving the data signalsthrough one or more movable readers, such as the handheld reader 724.

In an alternative embodiment, as described above, the receivingoperation (at 752) may occur with an on-board control system, such asthe control system 610 (FIG. 14).

The method 750 also included determining (at 754), based on the datasignals, whether the component of the machine is operating improperly.For example, the control system 720 may analyze the data signals and,optionally, other inputs to determine whether the component is operatingsufficiently. If the component is operating improperly, the method 750also includes generating (at 755) an operating plan that is based on thedata signals. The operating plan may be a new (or revised) operatingplan that is configured to replace a currently-implemented operatingplan. The method 750 may also include at least one of providingmaintenance (at 756) to the component or replacing (at 758) an elementof the component.

In an embodiment, a system (e.g., a monitoring system) is provided thatincludes a sensor configured to be disposed within a reservoir of amachine having moving parts that are lubricated by a liquid in thereservoir. The sensor is configured to obtain a measurement of theliquid that is representative of at least one of a quantity or qualityof the liquid in the reservoir. The system may also include a devicebody operably coupled to the sensor. The device body has a processingunit that is operably coupled to the sensor and configured to generatefirst data signals representative of the measurement of the liquid. Thedevice body also includes a transmitter that is configured to wirelesslycommunicate the first data signals to a remote reader.

In one aspect, the transmitter is configured to be energized by thereader when the reader interrogates the transmitter.

In one aspect, the system includes a power source that is configured tosupply power to the transmitter for transmitting the data signals. Thepower source may include, for example, a battery and/or energyharvesting device.

In one aspect, the sensor is configured to be at least partiallysubmerged in the liquid.

In one aspect, the measurement is at least one of a capacitance of theliquid, a temperature of the liquid, a fluid conduction of the liquid, adielectric constant of the liquid, an impedance of the liquid, or aviscosity of the liquid.

In one aspect, the device body is configured to be affixed to a wall ofthe machine in which the wall at least partially defines the reservoir.

In one aspect, the sensor and the device body collectively form a firstwireless device. The system may also include a second wireless devicethat is configured to obtain and wirelessly communicate second datasignals that are representative of a measurement of a differentreservoir.

In one aspect, the sensor is configured to be disposed in a gear case ofa locomotive, the gear case having the reservoir.

In one aspect, the transmitter is included in a radio-frequencyidentification (RFID) element.

In one aspect, the sensor, the processing unit, and the transmittercollectively form a first wireless device. The system may also include asecond wireless device that is configured to obtain and wirelesslytransmit data signals that are representative of a measurement of adifferent reservoir. The system may include a signal-processing module.The signal-processing module may be configured to determine, based onthe data signals, whether the machine is operating improperly bycomparing the data signals of the first wireless device to the datasignals of the second wireless device.

In one aspect, the data signals are configured to be transmitted to ahandheld reader. In another aspect, the data signals are configured tobe transmitted to a fixed reader located along a railway track. In yetanother aspect, the data signals are configured to be transmitted to anon-board reader located on a locomotive.

In one aspect, the sensor includes a multi-conductor capacitive sensorconfigured to detect a capacitance of a fluid. The fluid may function asa dielectric, wherein a level of the fluid affects the capacitancedetected. In another aspect, the sensor includes a body float and aposition transducer configured to detect a position of the body float.The position transducer may include, for example, a reed switch.

In an embodiment, a system (e.g., a monitoring system) is provided thatincludes a sensor that is configured to be engaged to a mechanicalelement of a drive train to obtain a measurement of a vibratory state ofthe mechanical element. The measurement is representative of anoperative condition of the drive train. The system includes a devicebody that has a processing unit operably coupled to the sensor. Theprocessing unit is configured to generate first data signalsrepresentative of the measurement. The device body also includes atransmitter that is configured to wirelessly communicate the first datasignals to a remote reader.

In one aspect, the system includes a power source configured to supplypower to the transmitter for transmitting the data signals.

In one aspect, the system includes a memory. The memory is configured tolog a plurality of the measurements obtained at different times. Thetransmitter is configured to transmit data signals that include themeasurements.

In one aspect, the sensor, the processing unit, and the transmittercollectively form a first wireless device. The system may include asecond wireless device configured to obtain and wirelessly transmit datasignals that are based on a measurement of a different drive train.

In one aspect, the device body includes a radio-frequency identification(RFID) unit. The RFID unit may have the processing unit and thetransmitter.

In an embodiment, a method (e.g., a method for monitoring an operativecondition of a machine) includes receiving data signals from a wirelessdevice of a machine having a drive train. The wireless device includes adevice body directly coupled to the drive train. The device bodyincludes a transmitter for wirelessly transmitting the data signals. Thedata signals may be based on a measurement of an operative condition ofthe drive train. The method also includes, responsive to determiningthat the drive train is operating improperly, generating signals toschedule at least one of maintenance of the drive train or replacementof an element of the drive train.

In one aspect, the measurement is representative of vibratory state of agear case or a liquid condition of a lubricant held in the gear case.

In one aspect, the measurement is at least one of a vibrationmeasurement of a gear case, a capacitance of a lubricant stored by thegear case, a temperature of the lubricant, a fluid conduction of thelubricant, a dielectric constant of the lubricant, impedance of thelubricant, or a viscosity of the lubricant.

In one aspect, the data signals are received from a plurality ofwireless devices. The data signals are based on a common type ofmeasurement.

In one aspect, the data signals are received at a handheld reader.

In one aspect, the machine is a locomotive and the data signals arereceived at a fixed reader located along a railway track.

In one aspect, the machine is a locomotive and the data signals arereceived at a reader located on-board the locomotive.

In one aspect, the method also includes operating the machine accordingto a first operating plan and generating a second operating plan that isbased on the operative condition.

In an embodiment, a system (e.g., a monitoring system) includes asignal-processing module that is configured to receive data signals froma wireless device of a machine having a drive train. The data signalsare based on a measurement of an operative condition of the drive train.The signal-processing module is configured to determine, based on thedata signals, whether the drive train is operating improperly.Optionally, the system also includes a planning module that isconfigured to generate an operating plan that is based on the operativecondition.

In another embodiment, a system (e.g., wireless liquid monitoringsystem) comprises a sensor, a processing unit, and a transmitter. Thesensor is configured to be disposed within a reservoir of a machinehaving moving parts that are lubricated by a liquid in the reservoir.The sensor is configured to obtain a measurement of the liquid that isrepresentative of at least one of a quantity or quality of the liquid inthe reservoir. The processing unit is operably coupled to the sensor andconfigured to generate first data signals representative of themeasurement of the liquid. The transmitter is operably coupled to theprocessing unit and configured to wirelessly communicate the first datasignals to a remote reader.

In another embodiment of the system, alternatively or additionally, thetransmitter is an RFID unit, which may be, for example, similar to anRFID tag, chip, card, or label.

In another embodiment of the system, alternatively or additionally, thesystem is configured to be disposed in the machine (and when installedis actually disposed in the machine), which comprises a vehicle or otherpowered system comprising the reservoir, the moving parts, and one ormore computers or other controller-based units (e.g., a vehiclecontroller) other than the processing unit. The system may not bephysically electrically connected (e.g., not connected by wires or otherconductors) to any of the one or more computers or othercontroller-based units in the machine. Thus, the first data signals mayonly be wirelessly transmitted from the system to the reader orelsewhere, and are not transmitted via wire/cables or other physicalelectrical connections.

In another embodiment of the system, alternatively or additionally, theprocessing unit and transmitter are co-located proximate to one another(e.g., at least partially integrated onto a common circuit board,positioned within a common box/housing that is positioned within themachine—that is, the common box/housing is not coextensive with theouter body/structure of the machine, but is located within the outerbody/structure—and/or some or all of the components of the processingunit and transmitter are located within 10 cm of each other, within 5 cmof each other, etc., for example), and/or at least portions of theprocessing unit and transmitter are directly connected to a wall of thereservoir (e.g., a wall that bears a pressure of and/or contacts theliquid in the reservoir) and/or to a structure immediately connected tosuch a wall (e.g., support structure of the reservoir, gear case, or thelike).

In another embodiment of the system, alternatively or additionally, thetransmitter is configured to wirelessly communicate the first datasignals to the remote reader that comprises: a remote reader locatedwithin the machine (e.g., if the machine is a vehicle, the remote readeris located with the vehicle); a remote reader located on a wayside of aroute of the machine, the machine comprising a vehicle; a portable(handheld, or otherwise able to be carried by a human operator) remotereader.

As used herein, an element or step recited in the singular and proceededwith the word “a” or “an” should be understood as not excluding pluralof said elements or steps, unless such exclusion is explicitly stated.Furthermore, references to “one embodiment” of the presently describedinventive subject matter are not intended to be interpreted as excludingthe existence of additional embodiments that also incorporate therecited features. Moreover, unless explicitly stated to the contrary,embodiments “comprising,” “including,” or “having” (or like terms) anelement, which has a particular property or a plurality of elements witha particular property, may include additional such elements that do nothave the particular property.

As used herein, terms such as “system,” “module,” or “controller” mayinclude hardware and/or software that operate(s) to perform one or morefunctions. For example, a system, module, or controller may include acomputer processor or other logic-based device that performs operationsbased on instructions stored on a tangible and non-transitory computerreadable storage medium, such as a computer memory. Alternatively, asystem, module, or controller may include a hard-wired device thatperforms operations based on hard-wired logic of the device. Thesystems, modules, and controllers shown in the Figures may represent thehardware that operates based on software or hardwired instructions, thesoftware that directs hardware to perform the operations, or acombination thereof.

As used herein, terms such as “operably connected,” “operativelyconnected,” “operably coupled,” “operatively coupled” and the likeindicate that two or more components are connected in a manner thatenables or allows at least one of the components to carry out adesignated function. For example, when two or more components areoperably connected, one or more connections (electrical and/or wirelessconnections) may exist that allow the components to communicate witheach other, that allow one component to control another component, thatallow each component to control the other component, and/or that enableat least one of the components to operate in a designated manner.

It is to be understood that the subject matter described herein is notlimited in its application to the details of construction and thearrangement of elements set forth in the description herein orillustrated in the drawings hereof. The subject matter described hereinis capable of other embodiments and of being practiced or of beingcarried out in various ways. Also, it is to be understood that thephraseology and terminology used herein is for the purpose ofdescription and should not be regarded as limiting. The use of“including,” “comprising,” or “having” and variations thereof herein ismeant to encompass the items listed thereafter and equivalents thereofas well as additional items.

It is to be understood that the above description is intended to beillustrative, and not restrictive. For example, the above-describedembodiments (and/or aspects thereof) may be used in combination witheach other. In addition, many modifications may be made to adapt aparticular situation or material to the teachings of the presentlydescribed subject matter without departing from its scope. While thedimensions, types of materials and coatings described herein areintended to define the parameters of the disclosed subject matter, theyare by no means limiting and are exemplary embodiments. Many otherembodiments will be apparent to one of ordinary skill in the art uponreviewing the above description. The scope of the inventive subjectmatter should, therefore, be determined with reference to the appendedclaims, along with the full scope of equivalents to which such claimsare entitled. In the appended claims, the terms “including” and “inwhich” are used as the plain-English equivalents of the respective terms“comprising” and “wherein.” Moreover, in the following claims, the terms“first,” “second,” and “third,” etc. are used merely as labels, and arenot intended to impose numerical requirements on their objects. Further,the limitations of the following claims are not written inmeans—plus-function format and are not intended to be interpreted basedon 35 U.S.C. § 112, sixth paragraph, unless and until such claimlimitations expressly use the phrase “means for” followed by a statementof function void of further structure.

This written description uses examples to disclose several embodimentsof the inventive subject matter, and also to enable one of ordinaryskill in the art to practice the embodiments of inventive subjectmatter, including making and using any devices or systems and performingany incorporated methods. The patentable scope of the inventive subjectmatter is defined by the claims, and may include other examples thatoccur to one of ordinary skill in the art. Such other examples areintended to be within the scope of the claims if they have structuralelements that do not differ from the literal language of the claims, orif they include equivalent structural elements with insubstantialdifferences from the literal languages of the claims.

What is claimed is:
 1. A system comprising: a sensor sized to be withina reservoir of a machine having moving parts that are lubricated by aliquid in the reservoir, the sensor configured to obtain a measurementof the liquid that is representative of one or more of a quantity or aquality of the liquid in the reservoir; and a device body operablycoupled with the sensor, the device body including a processing unit anda transponder, the transponder configured to wirelessly receive aninterrogation signal from a remote reader that also energizes theprocessing unit to generate a data signal representative of themeasurement of the liquid obtained by the sensor, the interrogationsignal additionally energizing the transponder to wirelessly communicatethe data signal to the remote reader.
 2. The system of claim 1, whereinthe sensor is configured to obtain the measurement of the liquidresponsive to receiving a query from the processing unit requesting themeasurement, the processing unit configured to communicate the query tothe sensor responsive to receiving the interrogation signal.
 3. Thesystem of claim 1, further comprising a power source configured tosupply power to the transponder for communicating the data signal. 4.The system of claim 1, wherein the sensor is configured to be at leastpartially submerged in the liquid.
 5. The system of claim 1, wherein themeasurement is at least one of a fluid level, a temperature of theliquid or nearby components, a fluid conduction of the liquid, adielectric constant of the liquid, an impedance of the liquid, or aviscosity of the liquid.
 6. The system of claim 1, wherein the machineis a vehicle and the reservoir is in a gear case of the vehicle.
 7. Thesystem of claim 1, wherein the device body is configured to be affixedto a wall of the machine, the wall at least partially defining thereservoir.
 8. The system of claim 1, wherein the remote reader comprisesat least one of a handheld reader, a fixed reader located along a route,or an on-board reader located on a vehicle.
 9. The system of claim 1,wherein the sensor comprises a multi-conductor capacitive sensorconfigured to detect a capacitance of the liquid with the liquidfunctioning as a dielectric, wherein a level of the liquid affects thecapacitance that is detected.
 10. The system of claim 1, wherein thesensor comprises a body float and a position transducer configured todetect a position of the body float.
 11. The system of claim 1, whereinthe sensor is configured to communicate data representative of themeasurement of the liquid to the processing unit as an analog signal,the processing unit including an analog-to-digital converter thatconverts the analog signal to a digital signal to generate the datasignal.
 12. The system of claim 1, wherein the sensor is a capacitivesensor configured to be disposed in contact with the liquid to obtain acapacitance measurement of the liquid, the system further comprising atemperature sensor operably coupled to the device body and disposed incontact with the liquid to obtain a temperature measurement of theliquid, the device body mounted to a wall of the reservoir and spacedapart from the liquid in the reservoir, the capacitive sensor and thetemperature sensor operably coupled to the device body via correspondingwires.
 13. The system of claim 1, further comprising a cable portionextending between the sensor and the device body, the cable portionconfigured to extend through a port of a wall of the machine, whereinthe wall at least partially defines the reservoir, the cable portionextending between a first end outside of the reservoir that is securedto the device body and a second end inside the reservoir that is securedto the sensor, the cable portion housing one or more wires extendingbetween the sensor and the device body to electrically connect thesensor to the device body.
 14. The system of claim 13, wherein the cableportion defines a fill channel that provides fluid access to thereservoir from outside of the wall.
 15. The system of claim 1, whereinthe device body includes an activator coupled to the processing unit,the activator configured to provide a stimulus that causes a response;and wherein the measurement of the liquid obtained is based on theresponse.
 16. A method comprising: receiving a measurement of a liquidin a reservoir of a machine having moving parts, the measurementrepresentative of one or more of a quantity or quality of the liquid inthe reservoir and obtained from a sensor disposed within the reservoir;wirelessly receiving an interrogation signal from a remote reader;generating, using electric energy of the interrogation signal, a datasignal representative of the measurement of the liquid obtained by thesensor based on a response; and wirelessly communicating, using theelectric energy of the interrogation signal, the data signal to theremote reader via a transponder.
 17. The method of claim 16, furthercomprising communicating a query to the sensor to obtain the measurementof the liquid responsive to receiving the interrogation signal.
 18. Asystem comprising: a sensor sized to be within a reservoir of a machinehaving moving parts that are lubricated by a liquid in the reservoir,the sensor configured to obtain a measurement of the liquid that isrepresentative of at least one of a quantity or quality of the liquid inthe reservoir; and a device body operably coupled to the sensor, thedevice body including a processing unit and a transponder, theprocessing unit configured to communicate a query to the sensorrequesting the sensor to obtain the measurement of the liquid responsiveto receiving an interrogation signal from a remote reader, theprocessing unit further configured to generate a data signalrepresentative of the measurement of the liquid obtained by the sensor,the transponder configured to wirelessly communicate the data signal tothe remote reader.
 19. The system of claim 18, wherein the transponderis configured to use electric energy of the interrogation signal toenergize the transponder to wirelessly communicate the data signal tothe remote reader.
 20. The system of claim 18, wherein the device bodyincludes an activator coupled to the processing unit, the activatorconfigured to provide a stimulus that causes a response; wherein themeasurement of the liquid obtained is based on the response.